Fibrous lining material comprising a primary layer having less fibrillated aramid fibers, carbon fibers, carbon particles and a secondary layer comprising carbon particles

Abstract

The present invention relates to a fibrous base material comprising a primary layer of less fibrillated aramid fibers, carbon particles, carbon fibers, phenolic novoloid fibers, and at least one filler material, optionally cotton fibers, and a secondary layer of carbon particles on at least one surface of the fibrous base material for use in a non-asbestos friction material. In certain embodiments, the fibrous base material is impregnated with a phenolic or phenolic-based resin material, including, for example, a mixture of a phenolic resin and a silicone resin to form a friction material having an extended high speed durability life, good "break-in" characteristics, good heat dissipation characteristics, and good noise or squawk resistance.

I claim: 
     
       1. A non-asbestos friction material comprising a fibrous base material impregnated with at least one curable resin; the fibrous base material comprising a porous primary layer and a secondary layer; the primary layer comprising, by weight, based on the primary layer about 10 to about 50% less fibrillated aramid fiber; about 5 to about 20% carbon particles; about 5 to about 25% carbon fibers; about 15 to about 35% filler material; about 0 to about 10% cotton fibers; and about 0.5 to about 5% phenolic novoloid fibers; the porous primary layer having an average pore diameter of about 2.0 to about 15 microns; the secondary layer comprising carbon particles on at least one surface of the primary layer, the carbon particles being present at about 0.2 to about 20%, by weight, based on the weight of the fibrous base material, the carbon particles covering about 3% to about 90% of the surface area of the primary layer. 
     
     
       2. The friction material of claim 1, wherein the primary layer comprises about 43% less fibrillated aramid fibers; about 20% carbon fibers; about 15% carbon particles, about 20% filler material; and about 2% novoloid phenolic fibers. 
     
     
       3. The friction material of claim 1, wherein the primary layer comprises less fibrillated aramid fibers having a freeness greater than about 450 on the Canadian Standard Freeness index, in an amount sufficient to provide high heat resistance and substantially uniform coefficient of friction to the friction material. 
     
     
       4. The friction material of claim 1, wherein the secondary layer comprises about 3% to about 5%, by weight, of carbon particles, based on the weight of the fibrous base material. 
     
     
       5. The friction material of claim 1, wherein the secondary layer comprises about 5% to about 15%, by weight, of carbon particles, based on the weight of the fibrous base material. 
     
     
       6. The friction material of claim 1, wherein the carbon particle size ranges from about 6 to about 50 microns. 
     
     
       7. The friction material of claim 1, wherein the area of coverage of the carbon particles on the primary layer is in the range of about 3 to about 80% of the surface area of the primary layer. 
     
     
       8. The friction material of claim 1, wherein the primary layer further comprises at least one retention aid to adhere the carbon particles on the surface of the primary layer. 
     
     
       9. The friction material of claim 8, wherein the retention aid comprises up to about 20% alum having a pH of about 4.5. 
     
     
       10. The friction material of claim 3, wherein the less fibrillated aramid fibers have a freeness of about 580-640 on the Canadian Standard Freeness index. 
     
     
       11. The friction material of claim 1, wherein the less fibrillated aramid fibers have average fiber lengths in the range of about 3 to about 6 mm. 
     
     
       12. The friction material of claim 1, wherein the filler comprises diatomaceous earth. 
     
     
       13. The friction material of claim 1, wherein the pore diameter ranges in mean average size from about 2.5 to about 12 microns. 
     
     
       14. The friction material of claim 1, wherein the primary layer has readily available air voids of at least about 50%. 
     
     
       15. The friction material of claim 1 impregnated with a phenolic resin or a modified phenolic resin. 
     
     
       16. The friction material of claim 15, wherein the friction material comprises approximately 25 to about 60% resin, by weight. 
     
     
       17. The friction material of claim 1, wherein the fibrous base material has been impregnated with a mixture of a phenolic resin and a silicone resin wherein the amount of silicone resin in the mixture ranges from approximately 5 to approximately 80%, by weight, based on the weight of the mixture, the friction material exhibiting high heat resistance and substantially uniform coefficient of friction. 
     
     
       18. The friction material of claim 17, wherein the phenolic resin is present in a solvent material and the silicone resin is present in a solvent material which is compatible with the solvent material of the phenolic resin. 
     
     
       19. The friction material of claim 17, wherein the amount of silicone resin present in the silicone-phenolic resin mixture ranges from about 20 to about 25%, by weight, based on the weight of the mixture. 
     
     
       20. The friction material of claim 17, wherein the amount of silicone resin present in the silicone resin mixture ranges from about 15 to about 25%, by weight, based on the weight of the mixture. 
     
     
       21. The friction material of claim 15, wherein the modified phenolic resin comprises an epoxy phenolic resin. 
     
     
       22. The friction material of claim 21, wherein the amount of epoxy resin present in the epoxy phenolic resin ranges from about 5 to about 25%, by weight, based on the weight of the epoxy phenolic resin. 
     
     
       23. The friction material of claim 22, wherein the amount of epoxy resin present in the epoxy phenolic resin ranges from about 10 to about 15%, by weight, based on the weight of the epoxy phenolic resin. 
     
     
       24. A process for producing a non-asbestos friction material comprising coating about 3% to about 90% of the surface area of at least one surface of a porous fibrous base material having an average pore diameter of about 2.5 to about 12 microns with carbon particles, the carbon particles being present at about 0.2 to about 20%, by weight, based on the weight of the fibrous base material, impregnating the carbon coated fibrous base material with at least one phenolic resin or modified phenolic resin, and thereafter curing the impregnated carbon coated fibrous base material at a predetermined temperature for a predetermined period of time; wherein the fibrous base material comprises, in weight percent, based on the weight of the fibrous base material, about 10 to about 50% less fibrillated aramid fiber; about 5 to about 20% carbon particles; about 5 to about 20% carbon fibers; about 15 to about 35% filler material; about 3 to about 10% cotton fibers; and about 0.5 to about 5% phenolic novoloid fibers. 
     
     
       25. A process for producing a non-asbestos friction material comprising mixing a phenolic resin with a silicone resin, impregnating a fibrous base material with the silicone-phenolic resin mixture, the fibrous base material comprising a porous primary layer and a secondary layer; the primary layer comprising the primary layer, by weight, based on the primary layer about 10 to about 50% less fibrillated aramid fiber; about 5 to about 20% carbon particles; about 5 to about 25% carbon fibers; about 15 to about 35% filler material; about 0 to about 10% cotton fibers; and about 0.5 to about 5% phenolic novoloid fibers; the porous primary layer having an average pore diameter of about 2.0 to about 15 microns; the secondary layer comprising carbon particles on at least one surface of the primary layer, the carbon particles being present at about 0.2 to about 20%, by weight, based on the weight of the fibrous base material, the carbon particles covering about 3% to about 90% of the surface area of the primary layer; and, thereafter heating the carbon coated impregnated fibrous base material to cure the phenolic resin and the silicone resin.